Protective Headwear

ABSTRACT

A helmet includes a shell having a lower edge, and an edge support extending around the lower edge of the shell. The edge support has a greater structural rigidity than the shell. The helmet can further include a retention strap system, and the edge support can include at least one attachment to attach the retention strap system to the helmet. The attachment can, for example, include a seating, and the helmet can, for example, further include an abutment member removably seatable within the seating. The abutment member can be attachable to a strap of the retention strap system.

This application claims the benefit of priority from provisional Patent application No. 61/239,580 filed Sep. 3, 2009, the contents of which are incorporated herein in its entirety.

BACKGROUND

The following information is provided to assist the reader in understanding the technology, including protective headwear and related systems, devices and/or methods, disclosed below and the environment in which such protective headwear or related systems, devices and/or methods will typically be used. The terms used herein are not intended to be limited to any particular narrow interpretation unless clearly stated otherwise in this document. References set forth herein may facilitate understanding of the technology or the background. The disclosure of all references cited herein are incorporated by reference.

Protective headwear or helmets have been used in many environments to protect users from injury. For example, military and police helmets often include outer shells fabricated from ballistic resistant materials such as KEVLAR® materials available from DuPont. A webbing system is sometimes provided to suspend a helmet shell on the wearer's head. In a number of helmets, the suspension system is formed by moveable pads of different shapes and sizes that are positionable within the helmet in a configuration determined by the user (in accordance with the manufacturer's recommendation). Such a padding system is, for example, described in US Published Patent Application No. 2006/0260026, the disclosure of which is incorporated herein by reference.

As illustrated in FIGS. 1A through 1C some helmets 100 such as the MSA Advanced Combat Helmet available from Mine Safety Appliances Company of Pittsburgh, Pa. are provided with a retention system or chinstrap system 110 that is attached to helmet shell 120 via bolts 130 which pass through helmet shell 120 and cooperate with nuts 132 (see FIG. 1C), Retention system 110 assists in properly retaining helmet 100 on the user's head. A thin, rubber edge trim or guard 140 surrounds the bottom edge of helmet shell 120 to protect and provide a finished surface to the bottom edge of helmet shell 120. Accessories such as eyewear retention straps, lights and/or other accessories can also be attached to such helmets via bolts passing through helmet shell 120. If bolts 130 and/or other bolts become loose or are lost in the field, it can be difficult to make adjustments or repairs in the field (particularly under battle conditions). Even if a repair can be made, such repairs are often made incorrectly (for example, using substitute hardware that may be incorrectly sized). If a repair is not made or made incorrectly, the helmet may not be correctly retained and/or positioned on the head of the user, resulting in increased risk of injury.

As illustrated in FIG. 1C, specialized equipment may also be necessary for such adjustments or repairs. Moreover, great care must be taken during manufacture to ensure ballistic and/or structural integrity of helmet shell 120 in the areas through which bolts 130 pass. In that regard, drilling holes through helmet shell 120 can result in delamination of helmet shell 120 (which is typically formed from a plurality of layers of ballistic resistant materials) or weakening in the area of the holes.

The metal of bolts 130 can also present a danger. For example, if a primary projectile/bullet strikes one of bolts 130, the projectile can fragment resulting in a shrapnel danger to the user of helmet 100 and individuals surrounding the user. Moreover, bolt 130 can fragment, resulting in a dangerous secondary projectiles.

It is desirable to develop protective headwear or helmets (or related systems, devices and/or methods) that reduce or eliminate problems associated with currently available protective headwear or helmets and/or otherwise provide improved performance.

SUMMARY

In one aspect, a helmet includes a shell having a lower edge, and an edge support extending around the lower edge of the shell. The edge support has a greater structural rigidity than the shell. The helmet can further include a retention strap system, and the edge support can include at least one attachment to attach the retention strap system to the helmet. The attachment can, for example, include a seating, and the helmet can, for example, further include an abutment member removably seatable within the seating. The abutment member can be attachable to a strap of the retention strap system.

The edge support can include a plurality attachments, wherein each of the attachments includes a seating, and the helmet can further include a plurality of abutment members. Each abutment member can, for example, be removably seatable within one of the seatings. Each abutment member can be attachable to one strap of the retention strap system.

Each of the abutment members can, for example, be designed to fail under load before the edge support fails.

Each of the attachments can, for example, include an opening in a lower portion thereof which is adapted to pass one strap of the retention strap system therethrough before the one strap is attached to one of the abutment members. The attachments can, for example, be positioned on an inner side of the edge support.

The helmet can further include at least one connector on an outer side of the edge support to attach an article to the helmet.

The edge support can, for example, be formed separately from the shell and be attached to the lower edge.

The edge support can, for example, be molded from a monolithic piece of polymeric material.

The shell can, for example, be formed of ballistic resistant material. The shell can be formed to include no passages therethrough.

The material for the edge support can, for example, have an Izod impact strength of at least 10 ft-lb/in, at least 20 ft-lb/in, at least 30 ft-lb/in, at least 35 ft-lb/in or higher. The material for the edge support can, for example, have a tensile modulus of at least 650,000 psi, at least 800,000 psi, at least 1,000,000 psi, at least 1,200,000, at least 1,300,000 psi or even higher. The material for the edge support can, for example, have a flexural modulus of at least 500,000 psi, at least 700,000 psi, at least 1,000,000 psi, at least 1,100,000 psi or even higher. The material for the edge support can, for example, have a flexural strength of at least 20,000 psi, at least 24,000 psi, at least 30,000 psi, at least 35,000, at least 37,000 psi or even higher. In several embodiments, the edge support was formed from glass—(that is, glass fiber- or fiberglass-) filled nylon having various weight percent of glass fill. In a number of embodiments, 30% glass-filled nylon was, for example, used for the edge support.

The edge support can, for example, be formed from a material having an Izod impact strength of at least 30 ft-lb/in², a tensile modulus of at least 800,000 psi, a flexural modulus of at least 700,000 psi, and a flexural strength of at least 24,000 psi. The edge support can also be formed from a material having an Izod impact strength of at least 35 ft-lb/in², a tensile modulus of at least 1,200,000 psi, a flexural modulus of at least 1,100,000 psi, and a flexural strength of at least 35,000 psi. The material for the edge support can, for example, be a glass-filled nylon such as a glass-filled nylon having at least 30% by weight glass fill.

In another aspect, a helmet includes a shell having a lower edge, and an edge support extending around the lower edge of the shell. The edge support includes a first or inner member or wall extending around an inner wall of the shell and a second or outer member or wall extending around an outer wall of the shell. The inner wall of the edge support includes a plurality of attachments to which a retention strap system is connected. The outer wall includes at least one connector for attachment of an article to the helmet. The shell can, for example, be formed of ballistic resistant material. The shell can, for example, be formed to include no passages therethrough.

In a further aspect, a helmet includes a shell having a lower edge, and an edge support extending around the lower edge of the shell. The edge support includes an inner wall extending around an inner wall of the shell and an outer wall extending around an outer wall of the shell. The inner wall of the edge support includes a plurality of attachments to which a retention strap system is connected.

The protective headwear or helmets, as well as related systems, devices and/or methods, along with the attributes and attendant advantages thereof, will best be appreciated and understood in view of the following detailed description taken in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A illustrates a bottom view of a currently available combat helmet.

FIG. 1B illustrates a side view of the helmet of FIG. 1A.

FIG. 1C illustrates the procedure for attaching the retention strap system of the helmet of FIG. 1A to the helmet shell.

FIG. 2 illustrates a perspective of a protective helmet described herein.

FIG. 3 illustrates a perspective, exploded or disassembled view of the helmet of FIG. 2.

FIG. 4A illustrates a bottom view of the helmet of FIG. 2.

FIG. 4B illustrates a side view of the helmet of FIG. 2.

FIG. 4C illustrates another perspective view of the helmet of FIG. 2.

FIG. 4D illustrates an enlarged, perspective view of the circled portion of FIG. 4C.

FIG. 5A illustrates a perspective view of the edge trim or guard of the helmet of FIG. 3.

FIG. 5B illustrates an enlarged perspective view of the encircled portion of the edge trim of FIG. 5A.

FIG. 6 illustrates a top plan view of the edge trim.

DETAILED DESCRIPTION

As used herein and in the appended claims, the singular forms “a,” “an”, and “the” include plural references unless the content clearly dictates otherwise. Thus, for example, reference to “an abutment member” includes a plurality of such abutment members and equivalents thereof known to those skilled in the art, and so forth, and reference to “the abutment member” is a reference to one or more such abutment members and equivalents thereof known to those skilled in the art, and so forth.

FIGS. 2 through 4D illustrate a protective helmet 200 including a generally dome-shaped helmet shell 210 and an edge trim 240 extending around a lower edge of helmet shell 200. The helmet suspension is shown in FIG. 4A, and can, for example, include pads 212 of a comfort padding system similar to or the same as that described in US Published Patent Application No. 2006/0260026.

Unlike edge trims on currently available helmets, edge trim 240 not only provides a finished surface to the bottom of helmet shell 210, but also adds structural rigidity to helmet shell 210 under, for example, side or front/back compression. Use of structural supporting helmet base or edge support 240, which can for example, be fabricated from high-strength, impact resistant polymeric material such as glass-filled or carbon-filled nylon, enables the use of a greater variety of materials for helmet shell 210 than is possible with currently available helmets. In that regard, the material for helmet shell 210 can, for example, have less structural strength than required of the materials for helmet shells of currently available helmets. In several embodiments, edge support 240 has greater structural rigidity than shell 210. The material or materials for helmet shell 210 can, for example, be chosen to provide greater ballistic protection, to reduce weight and/or to reduce manufacturing costs as compared to helmet shell materials used in currently available helmets. Suitable materials for helmet shell 210 include, but are not limited to, “aramid” (which is short for aromatic polyamide) materials and ultrahigh molecular weight polyethylene materials. Examples of suitable aramid materials include (i) KEVLAR® ballistic grade fibers/fabrics (formed from para-aramid synthetic fibers) available from E. I. du Pont de Nemours and Company of Wilmington, Del. USA, (ii) GOLD FLEX® material, which is a roll product including four plies of unidirectional aramid fiber available from Honeywell, and (iii) TWARON® woven fabric (poly-paraphenylene terephthalamide) available from Teijin Aramid BV of Arnhem, The Netherlands. An example of a suitable ultrahigh molecular weight polyethylene material is DYNEEMA® composite material available from DSM Dyneema of Geleen, The Netherlands. In several representative embodiments, ultrahigh molecular weight polyethylene materials were used for helmet shell 210. Helmet shell 210 can, for example, be formed in a mold from a plurality of layers of ballistic resistant materials.

The material for edge support 240 can, for example, have an Izod impact strength of at least 10 ft-lb/in, at least 20 ft-lb/in, at least 30 ft-lb/in, at least 35 ft-lb/in or higher. The material for edge support 240 can, for example, have a tensile modulus of at least 650,000 psi, at least 800,000 psi, at least 1,000,000 psi, at least 1,200,000, at least 1,300,000 psi or even higher. The material for edge support 240 can, for example, have a flexural modulus of at least 500,000 psi, at least 700,000 psi, at least 1,000,000 psi, at least 1,100,000 psi or even higher. The material for edge support 240 can, for example, have a flexural strength of at least 20,000 psi, at least 24,000 psi, at least 30,000 psi, at least 35,000, at least 37,000 psi or even higher. In several representative embodiments, edge support 240 was formed from glass-filled nylon having various weight percent of glass fill as set forth in Table 1 below. In a number of representative embodiment, 30% glass-filled nylon was, for example, used for edge support 240 with good results.

TABLE 1 Glass fill % (by weight) 15 30 40 Izod impact strength (psi) 21 38 40 Tensile modulus (psi) 810,000 1,300,000 1,620,000 Flexural modulus (psi) 710,000 1,160,000 1,510,000 Flexural strength (psi) 24,5000 37,000 40,600

Increased durability of the material for edge support 240 as compared to edge trims of currently available helmets (which are typically formed from rubber materials), also reduces the risk of delamination and/or other degradation as a result of infiltration of contaminant(s) into ballistic helmet shell 210 via the exposed lower edge thereof. Edge support 240 can also increase overall ballistic performance of helmet shell 210 by restricting movement of the shell near the lower end or edge thereof (for example, by constricting fiber movement of certain ballistic materials).

In the illustrated embodiment, edge support 240 has a generally U-shaped cross section dimensioned to seat or encompass the lower edge of helmet shell 210. Edge trim 240 is show disconnected from helmet shell 210 in FIGS. 5A through 6. In that regard, edge support 240 includes an inner wall or abutment surface 242, an outer wall or abutment surface 244 and a lower, transverse member or abutment surface 246 extending between and connecting inner wall 242 and outer wall 244. As used here, terms such as “front”, “back”, “inner”, “outer”, “upper”, “lower”, and like terms refer to an orientation of helmet 200 (and components thereof) as worn by a user in an upright position. In several embodiments, edge support 240 is permanently attached to the lower edge of helmet shell 220 via, for example, an adhesive.

In addition to providing structural support to helmet shell 210, edge support 240 can also be provided with attachments 250 formed on inner wall 242 to, for example, attach a retention strap or chin strap system or assembly 300. In several embodiments, attachments 250 are formed as pockets or seatings into which an abutment member 310, which is attached to one of four strap ends 320, is slidably positionable. In that regard, strap end 320 is passed through an opening 252 in a lower end of attachment 250 and abutment member 310 is passed through a loop 322 formed at the end of strap end 320. Strap end 320 is seated in a generally central region or notch 312 formed in abutment member 310. The strap end/abutment member assembly is then slid into attachment 250 until the lower surface of abutment member 310 abuts a lower surface of attachment 250 on each side of abutment member 310.

Abutment members 310, which can be formed from a polymeric material such as nylon, are designed to fail under a certain load, before any damage to edge support 240 or to strap end 320. Further, upon failure, an abutment member or members 310 is easily replaced in the field using the procedures described in the previous paragraph without the use of special tools. Previously available chin strap assemblies, which are attached via bolts passing through the helmet shell, have sometimes failed as a result of one or more bolts coming loose, requiring specialized tools to fix the problem as illustrated in FIG. 1C. These specialized tools are not always available in the field.

In general, abutment members 310 and attachments 250 also require fewer parts than previous assemblies in which bolts have been used. The components of the system of FIGS. 2-5 of the present invention are also less costly and less labor intensive to assemble than currently available systems. Likewise, there is less risk of incorrect assembly when field repairs and assembly are required.

An adjustment system such as a buckle 330 is attached to a lower end of each strap end 320 to cooperate with and attach to an upper strap end 342 of a lower portion 340 of strap system 300, which cooperates with the user's head as known in the art.

As illustrated, for example, in FIGS. 2 through 4C, outer wall 244 can include connectors 260 for attachment of various head-borne equipment and/or accoutrements. In the illustrated embodiment, two eyewear retention straps 400 are shown attached to two connectors 260 on a rearward end of edge guard 240. The strap of goggles (not shown) can, for example, be passed through an upper loop 410 formed in holders 400. In the illustrated embodiment, holders 400 are attached to connectors 400 via a lower loop 420, which surrounds connector 260, and is formed using a snap 430. Various connectors or holders (not shown) can be attached to connector 260 to attach any number of items to helmet 200.

Edge support 240 can, for example, be molded (for example, injected molded) separately from helmet shell 210 from a polymeric or polymeric composite (for example, glass-filled nylon) material as a monolithic, single piece. After formation of edge support 240, edge support 240 can be attached to helmet shell 210 in any suitable manner such as by an adhesive.

The use of edge support 240 eliminates the requirement to form (for example, drill) holes or passages in helmet shell 210 and to pass connectors such as bolts 130 of FIGS. 1A and 1B through such passages in the helmet shell to attach retention strap systems and/or other equipment to helmet 200. Edge support 240 thereby eliminates problems associated with maintaining ballistic and/or structural integrity of the helmet shell in the vicinity of such pass-through connectors.

The foregoing description and accompanying drawings set forth representative embodiments of technology, including protective headwear or helmets, as well as related systems, devices and/or methods. Various modifications, additions and alternative designs will, of course, become apparent to those skilled in the art in light of the foregoing teachings without departing from the scope hereof, which is indicated by the following claims rather than by the foregoing description. All changes and variations that fall within the meaning and range of equivalency of the claims are to be embraced within their scope. 

1. A helmet, comprising: a shell having a lower edge, and an edge support extending around the lower edge of the shell, the edge support having greater structural rigidity than the shell
 2. The helmet of claim 1 further comprising a retention strap system, the edge support comprising at least one attachment to attach the retention strap system to the helmet.
 3. The helmet of claim 2 wherein the attachment comprises a seating, the helmet further comprising an abutment member removably seatable within the seating, the abutment member being attachable to a strap of the retention strap system.
 4. The helmet of claim 2 wherein the edge support comprises a plurality attachments, each of the attachments comprising a seating, the helmet further comprising a plurality of abutment members, each abutment member being removably seatable within one of the seatings, each abutment member being attachable to one strap of the retention strap system.
 5. The helmet of claim 4 wherein each of the abutment members is designed to fail under load before the edge support fails.
 6. The helmet of claim 4 wherein each of the attachments comprises an opening in a lower portion thereof which is adapted to pass one strap of the retention strap system thereththrough before the one strap is attached to one of the abutment members.
 7. The helmet of claim 6 wherein the attachments are positioned on an inner side of the edge support.
 8. The helmet of claim 7 further comprising at least one connector on an outer side of the edge support to attach an article to the helmet.
 9. The helmet of claim 8 wherein the edge support is formed separately from the shell and is attached to the lower edge.
 10. The helmet of claim 9 wherein the edge support is molded from a monolithic piece of polymeric material.
 11. The helmet of claim 1 further comprising at least one connector on an outer side of the edge support to attached an article to the helmet.
 12. The helmet of claim 1 wherein the shell is formed of ballistic resistant material.
 13. The helmet of claim 12 where the shell includes no passages therethrough.
 14. The helmet of claim 1 wherein the edge support is formed from a material having an Izod impact strength of at least 30 ft-lb/in², a tensile modulus of at least 800,000 psi, a flexural modulus of at least 700,000 psi, a flexural strength of at least 24,000 psi.
 15. The helmet of claim 1 wherein the edge support is formed from a material having an Izod impact strength of at least 35 ft-lb/in², a tensile modulus of at least 1,200,000 psi, a flexural modulus of at least 1,100,000 psi, a flexural strength of at least 35,000 psi.
 16. The helmet of claim 15 wherein the material is glass-filled nylon having at least 30% by weight glass fill.
 17. A helmet, comprising: a shell having a lower edge, and an edge support extending around the lower edge of the shell, the edge support comprising an inner wall extending around an inner wall of the shell and an outer wall extending around an outer wall of the shell, the inner wall of the edge support comprising a plurality of attachments to which a retention strap system is connected, the outer wall of the edge support comprising at least one connector for attachment of an article to the helmet.
 18. The helmet of claim 17 wherein the shell is formed of ballistic resistant material.
 19. The helmet of claim 17 where the shell includes no passages therethrough.
 20. A helmet, comprising: a shell having a lower edge, and an edge support extending around the lower edge of the shell, the edge support comprising an inner wall extending around an inner wall of the shell and an outer wall extending around an outer wall of the shell, the inner wall comprising a plurality of attachments to which a retention strap system is connected. 